Thermoforming & Vacuum Forming
Using eight thermoforming machines ranging from 2'x3' to 5'x9', we heat and vacuum-form plastic sheets into custom trays with tight tolerances, clean finishes, and fast lead times across a wide range of materials.
From material handling to OEM component packaging, Hill Plastics delivers precision-engineered custom plastic trays built to exact specifications. With 45+ years of thermoforming expertise, eight forming machines, and full in-house tooling capabilities, we support every stage—from prototype to high-volume production—ensuring consistent quality, competitive pricing, and on-schedule delivery for industries across the country.
We offer end-to-end plastic tray manufacturing—from mold design and prototyping to high-volume thermoforming and precision CNC trimming.
Using eight thermoforming machines ranging from 2'x3' to 5'x9', we heat and vacuum-form plastic sheets into custom trays with tight tolerances, clean finishes, and fast lead times across a wide range of materials.
Our two 5'x10' CNC trimming centers deliver precise contour cutting, edge finishing, and drilling on thermoformed trays, ensuring every part meets exact drawing specifications with repeatable dimensional accuracy.
We design and fabricate custom molds from wood, polyurethane, and aluminum using CNC-milled master patterns, enabling low-cost prototype tooling and robust production molds tailored to your tray design.
Our skilled fabrication team handles precision drilling, heat bending, bonding, fastener installation, and assembly—producing tray components and secondary operations to specification in any quantity.
From a customer concept to a review-ready part, we produce plastic tray prototypes using low-cost wood or polyurethane tooling, with master patterns typically completed in just a few weeks.
Our 4'x7' rotary thermoforming machine runs at 2.5x the speed of standard single-station equipment, enabling cost-effective, quality-controlled high-volume tray production at competitive pricing.
Our sales and engineering team—Brad and Cody Hill—work directly with you to evaluate your tray requirements, recommend the right plastic material (ABS, HDPE, PETG, KYDEX, and more) based on durability, chemical resistance, and application environment, and finalize design specifications.
See how Hill Plastics has delivered precision plastic trays for manufacturers across aerospace, telecom, medical, and industrial markets.
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
"Great value, family business, personal attention. Over the years, Cody, Brad, and Aubrey have become valued associates in my small enterprise. Willing to tackle design challenges. Get-her-done communications. Outreach to additional sources of expertise. These folks understand the inventive process. Cody for example is a Kickstarter supporter and is familiar..."
"Hill Plastics did a great job creating a substitute back window for my RV. I have a portable mini-split air conditioner that I use in extremely hot weather to supplement my RV’s own cooling power. The mini-split has an inside unit that blows the cold air and an outside condenser..."
For over four decades, Hill Plastics has been the trusted manufacturing partner for OEMs and engineers who need precision, reliability, and cost-effective plastic tray solutions.
Founded in 1977 in Lewisville, TX, our team brings decades of thermoforming knowledge to every custom tray project.
Eight thermoforming machines, two CNC trimming centers, and a rotary former at 2.5x standard speed support any production volume.
Wood and polyurethane prototype tooling keeps early-stage costs low, with aluminum production molds built for long-run precision.
We serve manufacturers nationwide—from design and prototyping through high-volume fulfillment—all from our 20,000 sq ft Texas facility.
Our experienced team guides every project from concept through delivery.
Sales & Engineering Team
Brad Hill brings deep expertise in plastic thermoforming design and materials engineering to every customer project. As a key member of Hill Plastics' sales and engineering team, Brad specializes in helping clients navigate the complexities of material selection—evaluating cost, impact requirements, durability, tensile strength, chemical resistance, and environmental factors to identify the optimal PS or HIPS grade for each unique application. He works closely with customers from initial concept through prototype approval, offering guidance on tooling design, process optimization, and production planning. Brad's hands-on approach ensures that every thermoformed component is engineered for performance, manufacturability, and cost-effectiveness. His commitment to collaborative problem-solving and technical precision has made him a trusted advisor to OEM manufacturers, aerospace clients, and medical device companies nationwide. With a focus on delivering turnkey solutions that meet exact specifications, Brad exemplifies Hill Plastics' dedication to quality, innovation, and customer success.
Sales & Engineering Team
Cody Hill is a skilled plastics engineer and sales professional with a passion for transforming customer ideas into precision-manufactured reality. As part of Hill Plastics' dedicated sales and engineering team, Cody provides expert consultation on product design, material selection, and tooling strategy for custom thermoforming projects. He leverages advanced CAD tools like SolidWorks to collaborate with clients on design refinements, ensuring optimal part geometry, wall thickness distribution, and draft angles for successful vacuum forming. Cody's technical knowledge spans the full spectrum of PS and HIPS materials, enabling him to recommend the best plastic grade based on application-specific demands such as impact resistance, rigidity, clarity, and cost. From rapid prototyping using low-cost tooling to scaling up for high-volume production runs, Cody guides customers through every phase of the manufacturing process with transparency and attention to detail. His proactive communication style and commitment to delivering on-time, on-budget results have earned him the trust of clients across aerospace, telecommunications, industrial equipment, and medical device sectors.
Hill Plastics works with a wide range of thermoplastic materials including ABS, High-Temperature ABS, UV-Resistant ASA/ABS, HDPE, PETG, Polystyrene, KYDEX, and decorative foil-laminated materials. Material selection is based on your tray's required impact resistance, tensile strength, chemical exposure, temperature range, and environmental conditions—our engineering team helps identify the best fit for your application.
Talk to our engineering team for a free consultation and project evaluation.
Based in Lewisville, Texas, Hill Plastics ships custom plastic trays to manufacturers and businesses across the entire United States.
Nationwide U.S.
Service Coverage
20,000+ Sq Ft
Manufacturing Facility
Mon–Fri, 7AM–4:30PM
Business Hours
Contact us to discuss your requirements—we ship to customers across the U.S.
Established in 1977 with a proven track record in thermoforming.
Engineering and design powered by industry-standard SolidWorks software.
Custom QC system monitors every production stage for appearance and spec compliance.
Fill out the form below and our engineering team will respond promptly to discuss your tray specifications, material options, and production timeline. We're available Monday through Friday, 7AM–4:30PM CT.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.
For immediate assistance, feel free to give us a direct call at +1 972-436-9717. You can also send us a quick email at sales@hillplastics.com.